Fire retardant panel apparatus and method of making and using same

Abstract

A flame retardant panel apparatus, and method, utilize a flame retardant panel, having an exterior and an interior face thereof, with the panel including a panel structure having a primary core encapsulated within a panel frame of reinforced phenolic material, and a layer of flame retardant material attached to the panel structure and extending outwardly therefrom to at least partially define an exterior face of the flame retardant panel. The flame retardant panel is suitable for use in mass transit conveyances, such as subway cars, high speed cars, rail cars, buses, rapid response vehicles, marine vessels, and elevators.

1. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel, the layer of flame retardant material comprising:
 a secondary core of material from the group consisting of balsa wood, phenolic foam, and melamine foam, 
 an additional skin of reinforced phenolic material defining a first face thereof attached to the secondary core and a second face thereof opposite the secondary core, wherein the secondary core is sandwiched between and attached to the second skin of the composite support structure and the additional skin, and, with the additional skin being integrally joined to the remainder of the panel frame, to thereby fully encapsulate the secondary core within the reinforced phenolic material comprising the panel frame, and 
 a layer of intumescent material having a composite structure and comprising a coating containing an intumescent material bonded onto the second face of the additional skin, wherein the intumescent material is disposed in a fibrous mat; 
 
 wherein, the layer of intumescent material includes a cured epoxy resin to form a pre-cured layer of intumescent material, and the panel further includes an adhesive bonding the pre-cured layer of intumescent material to the second face of the additional skin. 
 
     
     
       2. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel, the layer of flame retardant material comprising:
 a secondary core of material from the group consisting of balsa wood, phenolic foam, and melamine foam, 
 an additional skin of reinforced phenolic material defining a first face thereof attached to the secondary core and a second face thereof opposite the secondary core, wherein the secondary core is sandwiched between and attached to the second skin of the composite support structure and the additional skin, and, with the additional skin being integrally joined to the remainder of the panel frame, to thereby fully encapsulate the secondary core within the reinforced phenolic material comprising the panel frame, and 
 a layer of intumescent material having a composite structure and comprising a coating containing an intumescent material bonded onto the second face of the additional skin, wherein the intumescent material is disposed in a fibrous mat; 
 
 wherein, the layer of intumescent material is impregnated with phenolic resin, placed against the second face of the additional skin of reinforced phenolic resin and co-cured therewith. 
 
     
     
       3. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins attached to the first and second faces of the primary core, one or more ribs of reinforced phenolic material connecting the first and second skins to one another and disposed inwardly from the periphery of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel 
 wherein:
 the panel defines a longitudinal axis thereof, a transverse axis thereof extending substantially perpendicularly to the longitudinal axis, and a thickness thereof extending substantially orthogonally to both the longitudinal and transverse axes of the panel, with both the longitudinal and transverse axes lying substantially within a plane defined by the interior face of the panel; and 
 the first and second skins comprise a stitched composite reinforcing structure of fibrous material, impregnated with phenolic resin; 
 the reinforcing structure of the skins having first second and third layers, the first layer being disposed adjacent the primary core and comprised of substantially randomly directed fibers, the second layer being disposed against the first layer and comprising substantially longitudinally directed fibers, and the third layer being disposed against the second layer and comprising substantially transversely directed fibers, with the first, second, and third layers being stitched together by stitching extending at least partially orthogonally to the longitudinal and transverse axes. 
 
 
     
     
       4. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel; and 
 a heating element adjacent the interior face of the panel. 
 
     
     
       5. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel, 
 wherein the panel defines a longitudinal axis thereof, a transverse axis thereof extending substantially perpendicularly to the longitudinal axis, and a thickness thereof extending substantially orthogonally to both the longitudinal and transverse axes of the panel, with both the longitudinal and transverse axes lying substantially within a plane defined by the interior face of the panel, 
 wherein the thickness of the panel varies and includes at least a first and a second thickness thereof, within the periphery of the primary core, and 
 wherein the layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel extends across the entirety of the exterior face of the panel, throughout both the first and second thicknesses of the panel. 
 
     
     
       6. The flame retardant panel of any one of  claim 1 ,  2 ,  4 , or  5 , further comprising, one or more ribs of reinforced phenolic material connecting the first and second skins to one another and disposed inwardly from the periphery of the primary core. 
     
     
       7. The flame retardant core of  claim 6 , wherein, the primary core is a pre-cured reinforced core, including at least one reinforced phenolic rib and two or more foam strips, the at least one phenolic rib being positioned between two adjacent ones of the two or more foam strips. 
     
     
       8. The flame retardant panel of any one of  claim 1 ,  2 ,  3 ,  4 , or  5 , wherein, one or more of the one or more closeouts is machineable to include at least one mating surface. 
     
     
       9. The flame retardant panel of  claim 8 , wherein, the mating surface is a lap joint. 
     
     
       10. The flame retardant panel of  claim 9 , wherein, the interior face of the panel defines a plane of the panel, the closeout includes at least one bore therethrough extending substantially perpendicularly to the plane of the panel. 
     
     
       11. The flame retardant panel of any one of  claim 1 ,  2 ,  3 ,  4 , or  5 , wherein, the primary core further comprises at least one tapping block, with the tapping block including a block of reinforced phenolic material and a metal plate encapsulated within the block, the tapping plate being adapted to be drilled and tapped so as to provide the panel with a mounting area. 
     
     
       12. The flame retardant panel of any one of  claim 1 ,  2 ,  3 ,  4 , or  5 , wherein, the primary core comprises a plastic closed cell foam of polyisocyanurate material. 
     
     
       13. The flame retardant panel of any one of  claim 1 ,  2 ,  3 ,  4 , or  5 , wherein, the primary core comprises a balsa wood material. 
     
     
       14. The flame retardant panel of  claim 4 , wherein, the heating element is embedded into the first skin of the panel, and integrally joined thereto by the phenolic material. 
     
     
       15. The flame retardant panel of  claim 5 , wherein, the layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel extends only partially across the entirety of the exterior face of the panel, throughout one but not both of the first and second thicknesses of the panel. 
     
     
       16. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel,
 wherein the panel defines a longitudinal axis thereof, a transverse axis thereof extending substantially perpendicularly to the longitudinal axis, and a thickness thereof extending substantially orthogonally to both the longitudinal and transverse axes of the panel, with both the longitudinal and transverse axes lying substantially within a plane defined by the interior face of the panel, 
 
 wherein the thickness of the panel varies and includes at least a first and a second thickness thereof, within the periphery of the primary core, and 
 wherein the layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel comprises:
 a first flame retardant structure in areas of the panel having the first thickness; and 
 a second flame retardant structure in areas of the panel having the second thickness. 
 
 
     
     
       17. The flame retardant panel of  claim 16 , wherein the first flame retardant structure of the layer of flame retardant material comprises, a secondary core of material from the group comprising balsa wood, phenolic foam, and melamine foam, and an additional skin of reinforced phenolic material, with the secondary core being sandwiched between and attached to the second skin of the composite support structure and the additional skin, and, with the additional skin being integrally joined to the remainder of the panel frame, to thereby fully encapsulate the secondary core within the reinforced phenolic material comprising the panel frame. 
     
     
       18. The flame retardant panel of  claim 17 , wherein, the second flame retardant structure of layer of flame retardant material comprises a layer of intumescent material attached to the second face of the second skin. 
     
     
       19. The flame retardant panel of  claim 18 , wherein, the layer of intumescent material is bonded onto the second face of the second skin. 
     
     
       20. The flame retardant panel of  claim 19 , wherein, the layer of intumescent material comprises a coating containing an intumescent material. 
     
     
       21. The flame retardant panel of  claim 19 , wherein, the layer of intumescent coating is a composite structure including an intumescent material disposed in a fibrous mat. 
     
     
       22. The flame retardant panel of  claim 21 , wherein, the layer of intumescent material includes a cured epoxy resin to form a pre-cured layer of intumescent material, and the panel further includes an adhesive bonding the pre-cured layer of intumescent material to the second face of the additional skin. 
     
     
       23. The flame retardant panel of  claim 21 , wherein, the layer of intumescent material is impregnated with phenolic resin, placed against the second face of the additional layer of reinforced phenolic resin and co-cured therewith. 
     
     
       24. A flame retardant panel, having an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, the flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the flame retardant panel; and 
 a conduit embedded within the panel and having first and second openings into the conduit through at least one of the interior or exterior faces or the perimeter of the panel. 
 
     
     
       25. A flame retardant panel apparatus, having multiple interconnected panels each including an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, with at least one of the panels of the flame retardant panel apparatus being a flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel, 
 wherein the flame retardant panel defines a longitudinal axis thereof, a transverse axis thereof extending substantially perpendicularly to the longitudinal axis, and a thickness thereof extending substantially orthogonally to both the longitudinal and transverse axes of the panel, with both the longitudinal and transverse axes lying substantially within a plane defined by the interior face of the panel, 
 wherein the thickness of the fire retardant panel varies and includes at least a first and a second thickness thereof, within the periphery of the primary core, and 
 wherein, the layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel extends across the entirety of the exterior face of the panel, throughout both the first and second thicknesses of the panel. 
 
     
     
       26. A flame retardant panel apparatus, having multiple interconnected panels each including an exterior face thereof adapted for attachment to a support frame and an interior face thereof adapted for defining a boundary of a compartment, with at least one of the panels of the flame retardant panel apparatus being a flame retardant panel comprising:
 a panel structure including a primary core encapsulated within a panel frame of reinforced phenolic material, the primary core having first and second faces thereof, and a periphery thereof, the panel frame including first and second skins, attached to the first and second faces of the primary core, and one or more closeouts disposed between the skins about the periphery of the primary core, with the one or more closeouts being attached to the periphery of the primary core and to the first and second skins; and 
 a layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel, 
 wherein the flame retardant panel defines a longitudinal axis thereof, a transverse axis thereof extending substantially perpendicularly to the longitudinal axis, and a thickness thereof extending substantially orthogonally to both the longitudinal and transverse axes of the panel, with both the longitudinal and transverse axes lying substantially within a plane defined by the interior face of the panel, 
 wherein the thickness of the fire retardant panel varies and includes at least a first and a second thickness thereof, within the periphery of the primary core, 
 and the flame retardant panel further comprises:
 a first flame retardant structure in areas of the panel having the first thickness; and 
 a second flame retardant structure in areas of the panel having the second thickness. 
 
 
     
     
       27. The flame retardant panel apparatus of any one of  claim 25  or  26 , wherein, the layer of flame retardant material comprises, a secondary core of material from the group comprising balsa wood, phenolic foam, and melamine foam, and an additional skin of reinforced phenolic material, with the secondary core being sandwiched between and attached to the second skin of the composite support structure and the additional skin, and, with the additional skin being integrally joined to the remainder of the panel frame, to thereby folly encapsulate the secondary core within the reinforced phenolic material comprising the panel frame. 
     
     
       28. The flame retardant panel apparatus of  claim 26 , wherein, the layer of flame retardant material attached to the second skin of the panel frame and extending outwardly therefrom to at least partially define the exterior face of the panel extends only partially across the entirety of the exterior face of the panel, throughout one, but not both of, the first and second thicknesses of the panel. 
     
     
       29. The flame retardant panel apparatus of any one of  claim 25  or  26 , wherein, the panel apparatus comprises a flooring apparatus of a conveyance. 
     
     
       30. The flame retardant panel apparatus of  claim 29 , wherein, the conveyance is an elevator including a floor support structure adapted for attachment thereto of the flooring apparatus. 
     
     
       31. The flame retardant panel apparatus of  claim 29 , wherein, the conveyance is a vehicle or vessel including a floor support structure adapted for attachment thereto of the flooring apparatus. 
     
     
       32. The flame retardant panel apparatus of  claim 31 , wherein, the vehicle or vessel is a mass transit vehicle or vessel.